Metal-modified silica particles for reducing odor

ABSTRACT

A substrate for reducing odor is provided. The substrate contains silica particles bonded to a transition metal through a covalent or coordinate bond. The transition metal provides one or more active sites for capturing an odorous compound.

RELATED APPLICATIONS

The present application is a divisional of U.S. application Ser. No.10/686,938, filed on Oct. 16, 2003, which is incorporated herein in itsentirety by reference thereto.

BACKGROUND OF THE INVENTION

Odor control additives have been conventionally incorporated intosubstrates for a variety of reasons. For instance, U.S. Pat. No.6,225,524 to Guarracino, et al. describes a substrate having an odorcontrol composition that includes an absorbent gelling material andsilica. Likewise, U.S. Pat. No. 6,376,741 to Guarracino, et al.describes a substrate having an odor control composition that includessilica and a zeolite (i.e., crystalline aluminosilicate). For instance,one type of silica said to be preferred in Guarracino, et al. ('524patent) is amorphous silica having a particle size of 4-12 microns and apore volume of 1-2 g/ml. Another type of preferred silica is said to bea silica gel having a medium pore diameter of from 90 to 110 angstroms,a surface area of from 250 m²/g to 350 m²/g, and an average particlesize of from 63 to 200 microns. Unfortunately, conventional odor controlcompositions, such as described above, have proven ineffective inobtaining the full level of odor control desired in many applications.

As such, a need exists for an odor control composition that may exhibitimproved odor control properties, particularly when applied to asubstrate.

SUMMARY OF THE INVENTION

In accordance with one embodiment of the present invention, a method forreducing odor is disclosed. The method comprises modifying the surfaceof silica particles with a transition metal so that the silica particlesare bonded to the transition metal through a covalent or coordinatebond. The method further comprises contacting the modified silicaparticles with an odorous compound, the transition metal providing oneor more active sites for capturing the odorous compound.

Various techniques may be utilized to form the modified silicaparticles. In one embodiment, a salt of the transition metal is mixedwith the silica particles to form a transition metal/silica particlemixture. The pH of this mixture may be selectively adjusted, such as toa pH of 7 or greater, and in some instances, to a pH of from about 9 toabout 10. Such an increase in pH may have a variety of benefits. Forinstance, many silica sols are considered stable at a pH of greater thanabout 7, and particularly between a pH of 9-10. When dissolved in water,salts of transition metals are acidic (e.g., copper chloride has a pH ofapproximately 4.8). Thus, when such an acidic transition metal salt ismixed with a basic silica sol, the pH is lowered and the metal saltprecipitates on the surface of the silica particles. This compromisesthe stability of the silica particles. Further, at lower pH values, thenumber of silanol groups present on the surface of the silica particlesis reduced. Because the transition metal may bind to these silanolgroups, the capacity of the particles for the transition metal islowered at lower pH values. Thus, to ameliorate the pH-lowering affectcaused by the addition of an acidic transition metal salt (e.g., copperchloride), certain embodiments of the present invention employ selectivecontrol over the pH of the silica particles during mixing with thetransition metal.

The selective control over pH may be accomplished in a variety of ways.For instance, in one embodiment, urea thermal decomposition (i.e.,pyrolysis) may be used to increase pH to the desired value. Oneadvantage of using urea decomposition to control the pH of thetransition metal/silica mixture is the ability to easily manipulate pHas the metal and silica are mixed together. For instance, the pyrolysisof urea produces ammonia (NH₃) as a byproduct. In some embodiments ofthe present invention, the presence of this ammonia byproduct may beused to increase the pH of the transition metal/silica mixture to thedesired level. Besides urea decomposition, other techniques may also beemployed to selectively adjust the pH of the transition metal/silicamixture. For instance, in one embodiment, a buffer system containing analkali metal bicarbonate and an alkali metal carbonate may be employed.In another embodiment, a basic compound may be employed, such as sodiumhydroxide, potassium hydroxide, ammonium hydroxide, and so forth.

Other techniques may also be utilized to form the modified silicaparticles. For instance, organofunctional silanes may be used in someembodiments to bond the transition metal to the silica particle. Exampleof such silanes may include, for instance, organofunctionalalkoxysilanes, such as aminofunctional alkoxysilanes. Theorganofunctional silanes may be covalently bonded to the silicaparticles through the silanol groups (Si—OH) present on the surfacethereof. Specifically, the silicon atom of the silane may form acovalent bond with the oxygen of the silanol group. The organofunctionalgroup of the silane may also form a coordinate bond with the transitionmetal. For example, in one embodiment, copper may form a coordinate bondwith different amino groups present on aminopropyltriethoxysilanes.

In accordance with another embodiment of the present invention, asubstrate for reducing odor is disclosed. The substrate contains silicaparticles bonded to a transition metal through a covalent or coordinatebond, the transition metal providing one or more active sites forcapturing an odorous compound. In one embodiment, the substratecomprises a nonwoven, woven, or paper web. In one embodiment, thesubstrate may be incorporated into an absorbent article. For example,the absorbent article may include at least one liquid-transmissive layerand a liquid-absorbent core, wherein the substrate forms at least aportion of the liquid-transmissive layer, the liquid-absorbent core, orcombinations thereof. In addition, the absorbent article may include aliquid-transmissive liner, a liquid-transmissive surge layer, aliquid-absorbent core, and a vapor-permeable, liquid-impermeable outercover, the substrate forming at least a portion of the liner, surgelayer, absorbent core, outer cover, or combinations thereof. In anotherembodiment, the substrate may be incorporated into a paper product, suchas a bath tissue, facial tissue, paper towel, etc., or a facemask.

Other features and aspects of the present invention are discussed ingreater detail below.

DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS Definitions

As used herein, a “coordinate bond” refers to a shared pair of electronsbetween two atoms, wherein one atom supplies both electrons to the pair.

As used herein, a “covalent bond” refers to a shared pair of electronsbetween two atoms, wherein each atom supplies one electron to the pair.

As used herein, an “absorbent article” refers to any article capable ofabsorbing water or other fluids. Examples of some absorbent articlesinclude, but are not limited to, personal care absorbent articles, suchas diapers, training pants, absorbent underpants, adult incontinenceproducts, feminine hygiene products (e.g., sanitary napkins), swim wear,baby wipes, and so forth; medical absorbent articles, such as garments,fenestration materials, underpads, bandages, absorbent drapes, andmedical wipes; food service wipers; clothing articles; and so forth.Materials and processes suitable for forming such absorbent articles arewell known to those skilled in the art.

As used herein the term “nonwoven fabric or web” means a web having astructure of individual fibers or threads which are interlaid, but notin an identifiable manner as in a knitted fabric. Nonwoven fabrics orwebs have been formed from many processes such as for example,meltblowing processes, spunbonding processes, bonded carded webprocesses, etc.

As used herein, the term “meltblowing” refers to a process in whichfibers are formed by extruding a molten thermoplastic material through aplurality of fine, usually circular, die capillaries as molten fibersinto converging high velocity gas (e.g. air) streams that attenuate thefibers of molten thermoplastic material to reduce their diameter, whichmay be to microfiber diameter. Thereafter, the meltblown fibers arecarried by the high velocity gas stream and are deposited on acollecting surface to form a web of randomly disbursed meltblown fibers.Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 toButin, et al., which is incorporated herein in its entirety by referencethereto for all purposes. Generally speaking, meltblown fibers may bemicrofibers that may be continuous or discontinuous, are generallysmaller than 10 microns in diameter, and are generally tacky whendeposited onto a collecting surface.

As used herein, the term “spunbonding” refers to a process in whichsmall diameter substantially continuous fibers are formed by extruding amolten thermoplastic material from a plurality of fine, usuallycircular, capillaries of a spinnerette with the diameter of the extrudedfibers then being rapidly reduced as by, for example, eductive drawingand/or other well-known spunbonding mechanisms. The production ofspun-bonded nonwoven webs is described and illustrated, for example, inU.S. Pat. No. 4,340,563 to Appel, et al., U.S. Pat. No. 3,692,618 toDorschner, et al., U.S. Pat. No. 3,802,817 to Matsuki, et al., U.S. Pat.No. 3,338,992 to Kinney, U.S. Pat. No. 3,341,394 to Kinney, U.S. Pat.No. 3,502,763 to Hartman, U.S. Pat. No. 3,502,538 to Levy, U.S. Pat. No.3,542,615 to Dobo, et al., and U.S. Pat. No. 5,382,400 to Pike, et al.,which are incorporated herein in their entirety by reference thereto forall purposes. Spunbond fibers are generally not tacky when they aredeposited onto a collecting surface. Spunbond fibers can sometimes havediameters less than about 40 microns, and are often between about 5 toabout 20 microns.

DETAILED DESCRIPTION

Reference now will be made in detail to various embodiments of theinvention, one or more examples of which are set forth below. Eachexample is provided by way of explanation, not limitation of theinvention. In fact, it will be apparent to those skilled in the art thatvarious modifications and variations may be made in the presentinvention without departing from the scope or spirit of the invention.For instance, features illustrated or described as part of oneembodiment, may be used on another embodiment to yield a still furtherembodiment. Thus, it is intended that the present invention cover suchmodifications and variations.

In general, the present invention is directed to silica particlesconfigured to reduce various types of odors. The silica particles maypossess various forms, shapes, and sizes depending upon the desiredresult. For instance, the silica particles may be in the shape of asphere, crystal, rod, disk, tube, string, etc. The average size of thesilica particles is generally less than about 500 microns, in someembodiments less than about 100 microns, in some embodiments less thanabout 100 nanometers, in some embodiments from about 1 to about 50nanometers, in some embodiments from about 2 to about 50 nanometers, andin some embodiments, from about 4 to about 20 nanometers. As usedherein, the average size of a particle refers to its average length,width, height, and/or diameter.

The silica particles may have a surface area of from about 50 squaremeters per gram (m²/g) to about 1000 m²/g, in some embodiments fromabout 100 m²/g to about 600 m²/g, and in some embodiments, from about180 m²/g to about 240 m²/g. Surface area may be determined by thephysical gas adsorption (B.E.T.) method of Bruanauer, Emmet, and Teller,Journal of American Chemical Society, Vol. 60, 1938, p. 309, withnitrogen as the adsorption gas. If desired, the silica particles mayalso be relatively nonporous or solid. That is, the silica particles mayhave a pore volume that is less than about 0.5 milliliters per gram(ml/g), in some embodiments less than about 0.4 milliliters per gram, insome embodiments less than about 0.3 ml/g, and in some embodiments, fromabout 0.2 ml/g to about 0.3 ml/g. Without intending to be limited bytheory, it is believed that silica particles having such a small sizeand high surface area may improve the adsorption capability of thesilica for many odorous compounds. Moreover, it is believed that thesolid nature, i.e., low pore volume, of the silica particles may enhancethe uniformity and stability of the silica, without sacrificing its odoradsorption characteristics. Commercially available examples of silicananoparticles, such as described above, include Snowtex-C, Snowtex-O,Snowtex-PS, and Snowtex-OXS, which are available from Nissan Chemical ofHouston, Tex. Snowtex-OXS particles, for instance, have a particle sizeof from 4 to 6 nanometers, and may be ground into a powder having asurface area of approximately 509 square meters per gram.

Silica particles, such as described above, may possess units that may ormay not be joined together. Whether or not such units are joinedgenerally depends on the conditions of polymerization. For instance, theacidification of a silicate solution may yield Si(OH)₄. If the pH ofthis solution is reduced below 7 or if a salt is added, then the unitsmay tend to fuse together in chains and form a “silica gel.” On theother hand, if the pH is kept at a neutral pH or above 7, the units maytend to separate and gradually grow to form a “silica sol.” Such silicaparticles may generally be formed according to any of a variety oftechniques well known in the art, such as dialysis, electrodialysis,peptization, acid neutralization, and ion exchange. Some examples ofsuch techniques are described, for instance, in U.S. Pat. No. 5,100,581to Watanabe, et al.; U.S. Pat. No. 5,196,177 to Watanabe, et al.; U.S.Pat. No. 5,230,953 to Tsugeno, et al. and U.S. Pat. No. 5,985,229 toYamada, et al., which are incorporated herein in their entirety byreference thereto for all purposes.

In one particular embodiment, a silica sol is formed using anion-exchange technique. For exemplary purposes only, one suchion-exchange technique will now be described in more detail. Initially,an alkali metal silicate is provided that has a molar ratio of silicon(SiO₂) to alkali metals (M₂O) of from about 0.5 to about 4.5. Forinstance, sodium water glass may be utilized that has a molar ratio offrom about 2 to about 4. An aqueous solution of the alkali metalsilicate is obtained by dissolving it in water at a concentration of,for instance, from about 2 wt. % to about 6 wt. %. The alkali metalsilicate-containing aqueous solution may then be contacted with one ormore ion-exchange resins. For instance, the solution may first becontacted with a strong-acid to ion-exchange all the metal ions in theaqueous solution. Examples of such strong acids include, but are notlimited to, hydrochloric acid, nitric acid, sulfuric acid, and so forth.The contact may be accomplished by passing the aqueous solution througha column filled with the strong acid at a temperature of from about 0°C. to about 60° C., and in some embodiments, from about 5° C. to about50° C. After passing through the column, the resulting silicicacid-containing aqueous solution may have a pH value of from about 2 toabout 4. If desired, another strong acid may be added to the silicicacid-containing aqueous solution to convert the impurity metalcomponents into dissociated ions. This additional strong acid maydecrease the pH value of the resulting solution to less than about 2,and in some embodiments, from about 0.5 to about 1.8.

The metal ions and the anions from the strong acid may be removed fromthe solution by consecutive application of a strong acid (i.e.,cation-exchange resin) and strong base (anion-exchange resin). Examplesof suitable strong bases include, but are not limited to, sodiumhydroxide, potassium hydroxide, and so forth. As a result of thisconsecutive application, the silicic acid-containing aqueous solutionmay have a pH value of from about 2 to about 5. This acidic aqueoussolution may then be contacted with one or more additional strong basesto stabilize the solution at a pH value of from about 7 to about 9.

The stabilized silicic acid-containing aqueous solution is then fed to acontainer in which the liquid temperature is maintained at from about70° C. to about 100° C. This process results in an increase inconcentration of the silica to from about 30 wt. % to about 50 wt. %.The stable aqueous silica sol may then be consecutively contacted with astrong acid and strong base, such as described above, so that theresulting aqueous silica sol is substantially free from polyvalent metaloxides, other than silica. Finally, ammonia may be added to the aqueoussol to further increase its pH value to from about 8 to about 10.5,thereby forming a stable aqueous silica sol having a silicaconcentration of from about 30 wt. % to about 50 wt. %, a mean particlesize of from about 10 to about 30 nanometers, and that is substantiallyfree from any polyvalent metal oxides, other than silica.

In accordance with the present invention, the silica particles aremodified with one or more transition metals. Examples of some suitabletransition metals that maybe used in the present invention include, butare not limited to, scandium, titanium, vanadium, chromium, manganese,iron, cobalt, nickel, copper, zinc, silver, gold, and so forth. Singlemetallic, as well as dimeric, trinuclear, and cluster systems may beused. Without being limited by theory, it is believed that thetransition metal provides one or more active sites for capturing and/orneutralizing an odorous compound. Further, the presence of thetransition metal is also believed to help improve the Lewis acidity ofthe silica, thus rendering it more receptive to free electron pairs ofmany odorous compounds.

The transition metal may be incorporated onto the surface of the silicaparticles in a variety of ways. For instance, silica particles maysimply be mixed with a solution containing the appropriate transitionmetal in the form of a salt, such as those containing a copper ion(Cu⁺²), silver ion (Ag⁺), gold ion (Au⁺ and Au⁺³), iron (II) ion (Fe⁺²),iron (III) ion (Fe⁺³), and so forth. Such solutions are generally madeby dissolving a metallic compound in a solvent resulting in free metalions in the solution. Generally, the metal ions are drawn to andadsorbed onto the silica particles due to their electric potentialdifferences, i.e., they form an “ionic” bond. In many instances,however, it is desired to further increase the strength of the bondformed between the metal and silica particles, e.g., to form a“coordinate” and/or “covalent bond.” Although ionic bonding may stilloccur, the presence of coordinate or covalent bonding may have a varietyof benefits, such as reducing the likelihood that any of the metal willremain free during use (e.g., after washing). Further, a strongadherence of the metal to the silica particles also optimizes odoradsorption effectiveness.

Numerous techniques may be utilized to form a stronger bond between thetransition metal and silica particles. For example, silica sols aregenerally considered stable at a pH of greater than about 7, andparticularly between a pH of 9-10. When dissolved in water, salts oftransition metals are acidic (e.g., copper chloride has a pH ofapproximately 4.8). Thus, when such an acidic transition metal salt ismixed with a basic silica sol, the pH is lowered and the metal saltprecipitates on the surface of the silica particles. This compromisesthe stability of the silica particles. Further, at lower pH values, thenumber of silanol groups present on the surface of the silica particlesis reduced. Because the transition metal binds to these silanol groups,the capacity of the particles for the transition metal is lowered atlower pH values. Thus, to ameliorate the pH-lowering affect caused bythe addition of an acidic transition metal salt (e.g., copper chloride),certain embodiments of the present invention employ selective controlover the pH of the silica particles during mixing with the transitionmetal.

The selective control over pH may be accomplished using any of a varietyof well-known buffering systems known in the art. One such bufferingsystem utilizes urea thermal decomposition (i.e., pyrolysis) to increasepH to the desired value. The pyrolysis of urea is well known, and hasbeen described in, for instance, Study of the Urea Decomposition(Pyrolysis) Reaction and Importance to Cyanuric Acid Production, PeterM. Shaber, et al., American Laboratory (August 1999), which isincorporated herein in its entirety by reference thereto for allpurposes. For instance, to initiate the pyrolysis reaction, urea isfirst heated to its melting point of approximately 135° C. Withcontinued heating to approximately 150° C., the urea is vaporized(Eq. 1) and is then decomposed into ammonia and isocyanic acid (Eq. 2).The urea also reacts with the isocyanic acid byproduct to form biuret(Eq. 3).H₂N—CO—NH₂(m)+heat

H₂N—CO—NH₂(g)  (1)H₂N—CO—NH₂(g)+heat

NH₃(g)+HNCO(g)  (2)H₂N—CO—NH₂(m)+HNCO(g)

H₂N—CO—NH—CO—NH₂(s)  (3)Upon further heating, e.g., to about 175° C., the biuret referencedabove reacts with isocyanic acid to form cyanuric acid and ammonia (Eq.4), as well as ammelide and water (Eq. 5).H₂N—CO—NH—CO—NH₂(m)+HNCO(g)

CYA(s)+NH₃(g)  (4)H₂N—CO—NH—CO—NH₂(m)+HNCO(g)

ammelide(s)+H₂O(g)  (5)As the temperature is further increased, other reactions begin to occur.For instance, biuret may decompose back into urea and isocyanic acid.The urea produced is unstable at higher temperatures, and thus, willfurther decompose into ammonia and isocyanic acid. Urea and thebyproducts of the pyrolysis reaction will continue to react and furtherdecompose as the reaction mixture is heated.

One advantage of using urea decomposition to control the pH of thetransition metal/silica mixture is the ability to easily manipulate pHas the metal and silica are mixed together. For instance, as indicatedabove, the pyrolysis of urea produces ammonia (NH₃) as a byproduct. Insome embodiments of the present invention, the presence of this ammoniabyproduct may be used to increase the pH of the transition metal/silicamixture to the desired level. The amount of ammonia present in themixture may be easily controlled by selectively varying the amount ofurea reactant and the temperature to which the urea is heated. Forinstance, higher pyrolysis temperatures generally result in a greateramount of resulting ammonia due to the greater extent to which the ureaand its byproducts are decomposed.

Besides urea decomposition, other well-known buffering systems may alsobe employed in the present invention to increase the pH of thetransition metal/silica mixture to the desired level. For instance, inone embodiment, the buffering system may use an alkali metal bicarbonateand an alkali metal carbonate in a certain molar ratio. The alkali metalcations may be, for instance, sodium and/or potassium. In one particularembodiment, the buffering system employs sodium carbonate (Na₂CO₃) andsodium bicarbonate (NaHCO₃). In other embodiments of the presentinvention, the buffering system may simply involve adding a certainamount of a basic compound to the mixture, such as sodium hydroxide,potassium hydroxide, ammonium hydroxide, and so forth. Regardless of thetechnique for increasing the pH of the transition metal/silica mixture,the present inventors have discovered that the adjustment allowsstronger bonds to be formed between the transition metal and silicaparticles. Specifically, without intending to be limited by theory, itis believed that the transition metal is capable of forming covalentbonds with the silanol groups present on the silica particle surface. Inaddition, the higher pH increases the number of silanol groups availablefor binding and reduces salt precipitation, thereby enhancing bondingefficiency. Of course, due to the opposite charge of the transitionmetal and some types of silica particles, some binding via electrostaticattraction will also be present.

Apart from pH adjustment, other techniques may also be utilized tofurther enhance the strength of the bonds formed between the transitionmetal and the silica particles. For instance, coupling agents may beused to link the transition metal to the silica particle. Such couplingagents may be employed with or without the pH adjustment discussedabove. For instance, in some embodiments, an organofunctional silanecoupling agent may be used to link the transition metal to the silicaparticles. Some examples of suitable organofunctional silane couplingagents that may be used include, but are not limited to,vinyltrichlorosilane, vinyltrimethoxysilane, vinyltriethoxysilane,vinylmethyldichlorosilane, vinylmethyldimethoxysilane,vinylmethyldiethoxysilane, 5-hexenyltrimethoxysilane,3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane,3-glycidoxypropylmethyldimethoxysilane,3-glycidoxypropylmethyldiethoxysilane,3-(meth)acryloxypropyltrimethoxysilane,3-(meth)acryloxypropyltriethoxysilane,3-(meth)acryloxypropylmethyldimethoxysilane,3-(meth)acryloxypropylmethyldiethoxysilane,4-vinylphenyltrimethoxysilane, 3-(4-vinylphenyl)propyltrimethoxysilane,4-vinylphenylmethyltrimethoxysilane, 3-aminopropyltrimethoxysilane,3-aminopropyltriethoxysilane, 3-aminopropylmethyldimethoxysilane,3-aminopropylmethyldiethoxysilane,3-(2-aminoethyl)aminopropyltrimethoxysilane,3-mercaptopropyltrimethoxysilane, 3-mercaptopropyltriethoxysilane,3-mercaptopropylmethyldimethoxysilane,3-mercaptopropylmethyldiethoxysilane, and partial hydrolyzates thereof.Of these coupling agents, organofunctional alkoxysilanes, andparticularly aminofunctional alkoxysilanes (e.g.,3-aminopropyltriethyoxysilane), are preferred.

Generally speaking, the silane coupling agents may be covalently linkedto the silica particles through the silanol groups (Si—OH) present onthe surface thereof. Specifically, the silicon atom of the silanecoupling agent may form a covalent bond with the oxygen of the silanolgroup. Once the silane coupling agent is covalently linked to the silicaparticles, the organofunctional group may form a coordinate bond withthe transition metal. For example, in one embodiment, copper may form acoordinate bond with different amino groups present onaminopropyltriethoxysilane coupling agents. An example of this reactionmechanism is set forth below:

The present inventors have discovered that the coordinate complex formedbetween the transition metal and silane coupling agent is strong, andthus, reduces the likelihood that any free metal will be present duringuse (e.g., after washing).

The transition metal present on the surface of the silica particle ofthe present invention is believed to provide one or more active sitesfor capturing and/or neutralizing odorous compounds. The active sitesmay be free, or may be weak enough so that they are replaced by anodorous molecule when contacted therewith. In addition, the particlesstill have the large surface area that is useful in absorbing otherodorous compounds. For example, the silica particles of the presentinvention may be used in various applications to remove odorouscompounds, such as mercaptans (e.g., ethyl mercaptan), ammonia, amines(e.g., trimethylamine (TMA), triethylamine (TEA), etc.), sulfides (e.g.,hydrogen sulfide, dimethyl disulfide (DMDS), etc.), ketones (e.g.,2-butanone, 2-pentanone, 4-heptanone, etc.) carboxylic acids (e.g.,isovaleric acid, acetic acid, propionic acid, etc.), aldehydes,terpenoids, hexanol, heptanal, pyridine, and combinations thereof.

If desired, more than one type of transition metal may be bound to asilica particle. This has an advantage in that certain metals may bebetter at removing specific odorous compounds than other metals.Likewise, different types of modified silica particles may be used incombination for effective removal of various odorous compounds. In oneembodiment, for instance, copper-modified silica particles are used incombination with manganese-modified silica particles. By using twodifferent modified particles in combination, numerous odorous compoundsmay be more effectively removed. For example, the copper-modifiedparticle may be more effective in removing sulfur and amine odors, whilethe manganese-modified particle may be more effective in removingcarboxylic acids.

The ratio of the transition metal to the silica particles may beselectively varied to achieve the desired results. In most embodiments,for example, the ratio of the transition metal to the silica particlesis at least about 10:1, in some embodiments at least about 50:1, and insome embodiments, at least about 100:1. Generally speaking, the order inwhich the particles, buffer and/or coupling agent, and transition metalare mixed may be varied as desired. In some instances, the order ofmixing may actually affect the characteristics of the modified silicaparticles. For instance, in one embodiment, the buffer and/or couplingagent is first added to the silica particles, and then the transitionmetal is added.

If desired, the modified silica particles of the present invention maybe applied to a substrate. The substrate may provide an increasedsurface area to facilitate the adsorption of odorous compounds by theparticles. In addition, the substrate may also serve other purposes,such as water absorption. Any of a variety of different substrates maybe incorporated with the modified silica particles in accordance withthe present invention. For instance, nonwoven fabrics, woven fabrics,knit fabrics, wet-strength paper, film, foams, etc., may be applied withthe particles. When utilized, the nonwoven fabrics may include, but arenot limited to, spunbonded webs (apertured or non-apertured), meltblownwebs, bonded carded webs, air-laid webs, coform webs, hydraulicallyentangled webs, and so forth.

In some embodiments, for example, the modified silica particles may beutilized in a paper product containing one or more paper webs, such asfacial tissue, bath tissue, paper towels, napkins, and so forth. Thepaper product may be single-ply in which the web forming the productincludes a single layer or is stratified (i.e., has multiple layers), ormulti-ply, in which the webs forming the product may themselves beeither single or multi-layered. Normally, the basis weight of such apaper product is less than about 120 grams per square meter (gsm), insome embodiments less than about 80 gsm, in some embodiments less thanabout 60 grams per square meter, and in some embodiments, from about 10to about 60 gsm.

Any of a variety of materials can also be used to form the paper web(s)of the product. For example, the material used to make the paper productmay include fibers formed by a variety of pulping processes, such askraft pulp, sulfite pulp, thermomechanical pulp, etc. The pulp fibersmay include softwood fibers having an average fiber length of greaterthan 1 mm and particularly from about 2 to 5 mm based on alength-weighted average. Such softwood fibers can include, but are notlimited to, northern softwood, southern softwood, redwood, red cedar,hemlock, pine (e.g., southern pines), spruce (e.g., black spruce),combinations thereof, and so forth. Exemplary commercially availablepulp fibers suitable for the present invention include those availablefrom Kimberly-Clark Corporation under the trade designations“Longlac-19”. Hardwood fibers, such as eucalyptus, maple, birch, aspen,and so forth, can also be used. In certain instances, eucalyptus fibersmay be particularly desired to increase the softness of the web.Eucalyptus fibers can also enhance the brightness, increase the opacity,and change the pore structure of the web to increase its wickingability. Moreover, if desired, secondary fibers obtained from recycledmaterials may be used, such as fiber pulp from sources such as, forexample, newsprint, reclaimed paperboard, and office waste. Further,other natural fibers can also be used in the present invention, such asabaca, sabai grass, milkweed floss, pineapple leaf, and so forth. Inaddition, in some instances, synthetic fibers can also be utilized. Somesuitable synthetic fibers can include, but are not limited to, rayonfibers, ethylene vinyl alcohol copolymer fibers, polyolefin fibers,polyesters, and so forth.

If desired, the substrate may form all or a portion of an absorbentarticle. In one embodiment, for instance, the absorbent article includesa liquid-transmissive bodyside liner, a liquid-transmissive surge layerbelow the bodyside liner, a liquid-absorbent core below the surge layer,and a moisture vapor permeable, liquid impermeable outer cover below theabsorbent core. A substrate treated with the modified silica particlesof the present invention may be employed as any one or more of theliquid transmissive (non-retentive) and absorbent layers. An absorbentcore of the absorbent article, for instance, may be formed from anabsorbent nonwoven web that includes a matrix of hydrophilic fibers. Inone embodiment, the absorbent web may contain a matrix of cellulosicfluff fibers. One type of fluff that may be used in the presentinvention is identified with the trade designation CR1654, availablefrom U.S. Alliance, Childersburg, Ala., U.S.A., and is a bleached,highly absorbent sulfate wood pulp containing primarily soft woodfibers. In another embodiment, the absorbent nonwoven web may contain ahydroentangled web. Hydroentangling processes and hydroentangledcomposite webs containing various combinations of different fibers areknown in the art. A typical hydroentangling process utilizes highpressure jet streams of water to entangle fibers and/or filaments toform a highly entangled consolidated fibrous structure, e.g., a nonwovenfabric. Hydroentangled nonwoven fabrics of staple length fibers andcontinuous filaments are disclosed, for example, in U.S. Pat. No.3,494,821 to Evans and U.S. Pat. No. 4,144,370 to Bouolton, which areincorporated herein in their entirety by reference thereto for allpurposes. Hydroentangled composite nonwoven fabrics of a continuousfilament nonwoven web and a pulp layer are disclosed, for example, inU.S. Pat. No. 5,284,703 to Everhart, et al. and U.S. Pat. No. 6,315,864to Anderson, et al., which are incorporated herein in their entirety byreference thereto for all purposes.

Another type of suitable absorbent nonwoven web is a coform material,which is typically a blend of cellulose fibers and meltblown fibers. Theterm “coform” generally refers to composite materials comprising amixture or stabilized matrix of thermoplastic fibers and a secondnon-thermoplastic material. As an example, coform materials may be madeby a process in which at least one meltblown die head is arranged near achute through which other materials are added to the web while it isforming. Such other materials may include, but are not limited to,fibrous organic materials such as woody or non-woody pulp such ascotton, rayon, recycled paper, pulp fluff and also superabsorbentparticles, inorganic absorbent materials, treated polymeric staplefibers and so forth. Some examples of such coform materials aredisclosed in U.S. Pat. No. 4,100,324 to Anderson, et al.; U.S. Pat. No.5,284,703 to Everhart, et al.; and U.S. Pat. No. 5,350,624 to Georger,et al.; which are incorporated herein in their entirety by referencethereto for all purposes.

If desired, the absorbent nonwoven web may also contain a superabsorbentmaterial. Superabsorbents have the ability to absorb a great amount offluid in relation to their own weight. Typical superabsorbents used insanitary napkins may absorb anywhere from about 5 to about 60 timestheir weight in blood. Superabsorbent materials are produced in a widevariety of forms including, but not limited to, particles, fibers andflakes. Superabsorbents having a high mechanical stability in theswollen state, an ability to rapidly absorb fluid, and those having astrong liquid binding capacity, typically perform well in absorbentarticles. Hydroxyfunctional polymers have been found to be goodsuperabsorbents for this application. For example, a hydrogel-formingpolymer, such as a partially neutralized cross-linked copolymer ofpolyacrylic acid and polyvinyl alcohol, may be utilized. After thepolymer is formed, it is mixed with about a 1% anhydrous citric acidpowder. The citric acid has been found to increase the ability of thesuperabsorbent to absorb menses and blood. This is particularlybeneficial for use in a sanitary napkin or other feminine pads. Thefinely ground, anhydrous citric acid powder, which is void of water,along with trace amounts of fumed silica, is mixed with the polymer thatmay have been screened to an appropriate particle size. This mixture mayalso be formed into a composite or a laminate structure. Suchsuperabsorbents may be obtained from Dow Chemical and Stockhausen, Inc.,among others. This superabsorbent is a partially neutralized salt ofcross-linked copolymer of polyacrylic acid and polyvinyl alcohol havingan absorbency under load value above about 25. Some suitablesuperabsorbents are described in U.S. Pat. No. 4,798,603 to Meyers, etal., U.S. Pat. No. Re. 32,649 to Brandt, et al. and U.S. Pat. No.4,467,012 to Pedersen, et al., U.S. Pat. No. 4,604,313 and U.S. Pat. No.4,655,757 to McFarland, et al., U.S. Pat. No. 6,387,495 to Reeves, etal., as well as in published European Patent Application 0,339,461 toKellenberger.

As indicated above, the modified silica particles may also be applied toa liquid transmissive layer of the absorbent article, such as thebodyside liner or surge layer. Such liquid transmissive layers aretypically intended to transmit liquid quickly, and thus generally do notretain or absorb significant quantities of aqueous liquid. Materialsthat transmit liquid in such a manner include, but are not limited to,thermoplastic spunbonded webs, meltblown webs, bonded carded webs, airlaid webs, and so forth. A wide variety of thermoplastic materials maybe used to construct these non-retentive nonwoven webs, includingwithout limitation polyamides, polyesters, polyolefins, copolymers ofethylene and propylene, copolymers of ethylene or propylene with aC₄-C₂₀ alpha-olefin, terpolymers of ethylene with propylene and a C₄-C₂₀alpha-olefin, ethylene vinyl acetate copolymers, propylene vinyl acetatecopolymers, styrene-poly(ethylene-alpha-olefin) elastomers,polyurethanes, A-B block copolymers where A is formed of poly(vinylarene) moieties such as polystyrene and B is an elastomeric midblocksuch as a conjugated diene or lower alkene, polyethers, polyetheresters, polyacrylates, ethylene alkyl acrylates, polyisobutylene,poly-1-butene, copolymers of poly-1-butene including ethylene-1-butenecopolymers, polybutadiene, isobutylene-isoprene copolymers, andcombinations of any of the foregoing.

The amount of the modified silica particles present on the substrate mayvary depending on the nature of the substrate and its intendedapplication. In some embodiments, for example, the dry, solids add-onlevel is from about 0.001% to about 20%, in some embodiments from about0.01% to about 10%, and in some embodiments, from about 0.1% to about4%. The “solids add-on level” is determined by subtracting the weight ofthe untreated substrate from the weight of the treated substrate (afterdrying), dividing this calculated weight by the weight of the untreatedsubstrate, and then multiplying by 100%. Lower add-on levels may provideoptimum absorbency or other characteristics of the substrate, whilehigher add-on levels may provide optimum odor reduction.

The modified silica particles may be applied to a substrate using any ofa variety of well-known application techniques. Suitable techniques forapplying the composition to a substrate include printing, dipping,spraying, melt extruding, solvent coating, powder coating, and so forth.The modified silica particles may be incorporated within the matrix ofthe substrate and/or applied to the surface thereof. For example, in oneembodiment, the modified silica particles are coated onto one or moresurfaces of the substrate. When coated onto the substrate, the resultingthickness of the coating may be minimal so that it is almost invisibleto the naked eye. For instance, the thickness of the coating may be lessthan about 2 microns, in some embodiments from about 2 to about 500nanometers, and in some embodiments, from about 20 to about 200nanometers.

The percent coverage of the modified silica particles on the surface maybe selected to achieve the desired odor reduction. Typically, thepercent coverage is greater than about 50%, in some embodiments greaterthan about 80%, and in some embodiments, approximately 100% of the areaof a given surface. The present inventors have discovered that, evenwhen applied uniformly (e.g., about 100% coverage) onto a surface of thesubstrate, the resulting substrate may still remain porous.Specifically, without intending to be limited by theory, it is believedthat the small size of the modified silica particles limits theirability to block the pores of the substrate. Thus, in some instances, asubstrate containing the particle coating may remain porous to provide avariety of benefits. For instance, the porosity of the coated substratemay enable it to still be used in application where liquid permeabilityis required, such as in absorbent articles. Also, the porosity of thecoated substrate allows gaseous odorous compounds to flow therethrough,exposing the underside of the nanoparticles (surface of particles facingthe substrate) to the odorous compound. In this manner, the entiresurface area of the particles is more effectively utilized for reducingodor. In most embodiments, the coated substrate exhibits a porosity suchthat about 20 cubic feet of air or greater may flow through 1 squarefoot of the substrate in 1 minute under an air pressure differential of125 Pascals (0.5 inches of water). In other words, such a substrate issaid to have an air permeability of about 20 cubic feet per minute (cfm)or greater. In some embodiments, the air permeability ranges from about20 cfm to about 500 cfm, in some embodiments from about 50 cfm to about400 cfm, and in some embodiments, from about 75 cfm to about 300 cfm,under an air pressure differential of 125 Pascals. Air permeability(volumetric air flow per square foot of material under an air pressuredifferential of 125 Pascals) may be measured in a variety of ways. Forexample, “Frazier Air Permeability” is determined according to FederalTest Standard 191A, Method 5450 with a Frazier Air Permeability Tester(Frazier Precision Instrument Co., Gaithersburg, Md.), and is reportedas an average of 3 sample readings.

The modified silica particles of the present invention are versatile andmay also be used with other types of articles of manufacture. Forinstance, the modified silica particles may be used in air filters, suchas house filters, vent filters, disposable facemasks, and facemaskfilters. Exemplary facemasks, for instance, are described and shown, forexample, in U.S. Pat. Nos. 4,802,473; 4,969,457; 5,322,061; 5,383,450;5,553,608; 5,020,533; 5,813,398; and 6,427,693, which are incorporatedherein in their entirety by reference thereto for all purposes. In oneembodiment, a substrate coated with the silica particles of the presentinvention may be utilized as a filtration layer of the facemask.Filtration layers, such as meltblown nonwoven webs, spunbond nonwovenwebs, and laminates thereof, are well known in the art.

In another embodiment, the modified silica particles may be applied towalls, wallpaper, glass, toilets, and/or countertops. For instance, themodified silica particles may be used in a restroom facility. Other usesinclude, without limitation, refrigerator mats and fabric softenersheets.

The modified silica particles may also be applied to water treatmentsystems for removing sulphurous compounds from well water or in toilettanks to reduce the odors resulting from urine. The modified silicaparticles may also be used in liquid detergents and household cleanersto remove odors. In another embodiment, the modified silica particlesare used as aerosol odor neutralizers/deodorants. The modified silicaparticles are packaged with a propellant that allows spraying themodified silica particles into the air for removal of gases and odorouscompounds. The modified silica particles may be used in a household airfreshener or be used in combination with a mist emitted from a vaporizeror humidifier.

The effectiveness of the modified silica particles of the presentinvention may be measured in a variety of ways. For example, the percentof an odorous compound adsorbed by the modified silica particles may bedetermined in accordance with the headspace gas chromatography test setforth herein. In some embodiments, for instance, the modified silicaparticles of the present invention are capable of adsorbing at leastabout 25%, in some embodiments at least about 45%, and in someembodiments, at least about 65% of a particular odorous compound. Theeffectiveness of the modified silica particles in removing odors mayalso be measured in terms of “Relative Adsorption Efficiency”, which isalso determined using headspace gas chromatography and measured in termsof milligrams of odor adsorbed per gram of modified silica particle. Itshould be recognized that the surface chemistry of any one type ofmodified silica particle may not be suitable to reduce all types ofodors, and that low adsorption of one or more odorous compounds may becompensated by good adsorption of other odorous compounds.

The present invention may be better understood with reference to thefollowing examples.

Test Methods

Quantitative and qualitative odor tests were used in the Examples.Quantitative odor adsorption was determined in the Examples using a testknown as “Headspace Gas Chromatography.” Headspace gas chromatographytesting was conducted on an Agilent Technologies 5890, Series II gaschromatograph with an Agilent Technology 7694 headspace sampler (AgilentTechnologies, Waldbronn, Germany). Helium was used as the carrier gas(injection port pressure: 12.7 psig; headspace vial pressure: 15.8 psig;supply line pressure is at 60 psig). A DB-624 column was used for theodorous compound that had a length of 30 meters and an internal diameterof 0.25 millimeters. Such a column is available from J&W Scientific,Inc. of Folsom, Calif.

The operating parameters used for the headspace gas chromatography areshown below in Table 1:

TABLE 1 Operating Parameters for the Headspace Gas ChromatographyDevice. Headspace Parameters Zone Temps, ° C. Oven 37 Loop 42 TR. Line47 Event Time, minutes GC Cycle time 10.0 Vial eq. Time 10.0 Pressuriz.Time 0.20 Loop fill time 0.20 Loop eq. Time 0.15 Inject time 0.30 VialParameters First vial 1 Last vial 1 Shake [off]

The test procedure involved placing 5 milligrams of the modified silicaparticles in a 20-cubic centimeter headspace vial. Using a syringe, analiquot of the odorous compound was also placed in the vial. Testing wasdone with 839 micrograms of ethyl mercaptan (1 microliter), 804micrograms (1 microliter) of isovaleraldehyde, and 726 micrograms (1microliter) of triethylamine (TEA). Each sample was tested intriplicate. The vial was then sealed with a cap and a septum and placedin the headspace gas chromatography oven at 37° C. After two (2) hours,a hollow needle was inserted through the septum and into the vial. A1-cubic centimeter sample of the headspace (air inside the vial) wasthen injected into the gas chromatograph. Initially, a control vial withonly the aliquot of odorous compound was tested to define 0% odorouscompound adsorption. To calculate the amount of headspace odorouscompound removed by the sample, the peak area for the odorous compoundfrom the vial with the sample was compared to the peak area from theodorous compound control vial.

Qualitative odor reduction was also assessed against common odors, suchas garlic, cigarette and urine.

EXAMPLE 1

The ability to form modified silica particles was demonstrated. Thesilica particles were Snowtex-PSSO, which are colloidal silicananoparticles commercially available from Nissan Chemical America ofHouston, Tex. The particles have an average particle size of between 10to 20 nanometers and a surface area between 180 to 240 square meters pergram. The silica particles were modified with a transition metal asfollows. Initially, 3-aminopropyltriethyoxysilane (5 millimoles, 1.17milliliters) was dissolved in 50 milliliters of water and transferred toa 500-milliliter round bottom flask. A solution of the Snowtex-PSSOparticles (200 milliliters of a 2.6 wt. % solution) was slowly added tothe silane solution while vigorously stirring. The resultant reactantsolution was allowed to reflux for 48 hours, and then cooled to roomtemperature. Once the reactant solution was cooled, a solution of copperchloride (CuCl₂) (5 millimoles, 672 micrograms) in 50 milliliters ofwater was slowly added to the reactant solution and allowed to refluxfor 48 hours. The solution was allowed to cool to room temperature, andstirred at ambient conditions for another 48 hours. The solvent was thenremoved en vacuo. The resulting product, which was pale blue, was washedextensively with acetone, water, and acetone once again. The product wasdried overnight in a vacuum oven.

EXAMPLE 2

The effectiveness of the modified silica particles to adsorb odorouscompounds was demonstrated. The modified particles of Example 1 weretested for odor adsorption as described above. In addition, silicaparticles mixed with copper chloride without the use of a silanecoupling agent were also tested at a copper-to-silica ratio of 60:1.These samples were formed from Snowtex-PSSO, Snowtex-C, Snowtex-O, andSnowtex-AK silica nanoparticles, which are colloidal silicananoparticles commercially available from Nissan Chemical America ofHouston, Tex. The particles have an average particle size of between 10to 20 nanometers and a surface area between 180 to 240 square meters pergram. For comparative purposes, activated carbon (obtained from Aldrich)and RX 4483, which is precipitated calcium carbonate obtained fromSpecialty Minerals of New York, N.Y., were also tested.

The results are shown below in Table 2 in terms of milligrams of theodorous compound removed per gram of sample, i.e., relative adsorptionefficiency.

TABLE 2 Removal of Ethyl Mercaptan Relative Adsorption Efficiency Sample(mg odor removed/g sample) Copper-Modified Snowtex-PSSO 26.393 from Ex.1 Copper/Snowtex-C Mixture 13.413 Copper/Snowtex-O Mixture 21.139Copper/Snowtex-PSSO Mixture 13.906 Copper/Snowtex-AK Mixture 11.763 RX4483 5.546 Activated Carbon 22.677

As indicated, the present invention provided excellent adsorption ofethyl mercaptan.

EXAMPLE 3

The ability to form modified silica particles was demonstrated. Thesilica particles were Snowtex-C, which are colloidal silicananoparticles commercially available from Nissan Chemical America ofHouston, Tex. The particles have an average particle size of between 10to 20 nanometers and a surface area between 180 to 240 square meters pergram. A solution of the Snowtex-C particles (26.2 grams of a 20 wt. %solution, 8.47 micromoles of silica) was applied with a solution ofcopper nitrate (Cu(NO₃)₂) (317 milligrams, 1.69 millimoles) in 40milliliters of water. A solution of urea (102 milligrams, 1.69millimoles) in 160 milliliters of water was also applied to the mixture.The resultant reactant solution was allowed to reflux for 24 hours at105° C., and then cooled to room temperature. Once the reactant solutionwas cooled, the product was collected by centrifugation and washedextensively with portions of water and acetone. The product was driedovernight en vacuo.

EXAMPLE 4

The ability to form modified silica particles was demonstrated. Thesilica particles were Snowtex-C nanoparticles. A solution of theSnowtex-C particles (26.2 grams of a 20 wt. % solution, 8.47 micromolesof silica) was applied with a solution of copper nitrate (Cu(NO₃)₂) (317milligrams, 1.69 millimoles) in 40 milliliters of water. A solution ofammonium hydroxide (NH₄OH) (138 milligrams, 8.132 millimoles) in 160milliliters of water was also applied to the mixture. The resultantreactant solution was allowed to reflux for 24 hours at 105° C., andthen cooled to room temperature. Once the reactant solution was cooled,the product was collected by centrifugation and washed extensively withportions of water and acetone. The product was dried overnight en vacuo.

EXAMPLE 5

The ability to form modified silica particles was demonstrated. Thesilica particles were Snowtex-PSSO nanoparticles. A solution of theSnowtex-PSSO particles (27.99 grams of a 20 wt. % solution, 4.23micromoles of silica) was applied with a solution of copper nitrate(Cu(NO₃)₂) (403 milligrams, 2 millimoles) in 40 milliliters of water. ANa₂CO₃/NaHCO₃ buffer (pH of 9) was also applied to the mixture. Theresultant reactant solution was allowed to reflux for 24 hours at 105°C., and then cooled to room temperature. Once the reactant solution wascooled, the product was collected by centrifugation and washedextensively with portions of water and acetone. The product was driedovernight en vacuo.

EXAMPLE 6

The effectiveness of the modified silica particles of Examples 1 and 3-4to adsorb odorous compounds was demonstrated. In addition, silicaparticles mixed with copper chloride without the use of a pH adjustmentor a silane coupling agent were also tested at a copper-to-silica ratioof 60:1. These samples were formed from Snowtex-PSSO and Snowtex-C. Theresults are shown below in Table 3 in terms of milligrams of the odorouscompound removed per gram of sample, i.e., relative adsorptionefficiency.

TABLE 3 Removal of Ethyl Mercaptan Relative Adsorption Efficiency Sample(mg odor removed/g sample) Copper-Modified Snowtex-PSSO 37.730 from Ex.1 Copper-Modified Snowtex-C from 101.325 Ex. 3 Copper-Modified Snowtex-Cfrom 87.583 Ex. 4 Copper/Snowtex-C Mixture 27.788 Copper/Snowtex-PSSOMixture 8.037

As indicated, the present invention provided excellent adsorption ofethyl mercaptan.

EXAMPLE 7

The effectiveness of the modified silica particles of Example 1 toadsorb various odorous compounds was again demonstrated. The results areshown below in Table 4 in terms of milligrams of the odorous compoundremoved per gram of sample, i.e., relative adsorption efficiency.

TABLE 4 Removal of Ethyl Mercaptan, Isoveraldehyde, and TriethylamineRelative Adsorption Efficiency Relative Adsorption of Ethyl Efficiencyof Relative Adsorption Mercaptan (mg Isoveraldehyde (mg Efficiency ofTEA odor removed/ odor removed/g (mg odor removed/ Sample g sample)sample) g sample) Copper- 84.81 65.17 52.21 Modified Snowtex- PSSO fromEx. 1

EXAMPLE 8

The potential to modify silica particles with an insoluble layer ofcopper hydroxide was demonstrated. The silica particles wereSnowtex-OXS, which are colloidal silica nanoparticies commerciallyavailable from Nissan Chemical America of Houston, Tex. The particleshave an average particle size of between 4 to 6 nanometers and a surfacearea between 180 to 240 square meters per gram. A solution of theSnowtex-OXS particles (10 wt. % solution) was initially adjusted to pHof 8.7, and then a solution of 1 Molar copper chloride was added withhigh shear mixing (10,000 rpm). The pH, Zeta potential and particle sizewere all monitored during addition of the copper salt. When a positiveZeta Potential was obtained, the addition of copper salt was stopped. Acontrol sample of copper hydroxide suspension was also prepared in asimilar manner. The results are shown below in Table 5.

TABLE 5 Properties of Samples Zeta Potential Particle Size Surface AreaSample pH (mV) (nm) (m²/g) Snowtex-OXS 8.7 −55 9 509 Snowtex-OXS/ 8.6 3843 508 Cu(OH)₂ Cu(OH)₂ 8.5 −8 36,735 Not Determined

The above results clearly show a successful coating of the copperhydroxide onto the silica surface resulting in a positively chargedparticle having a small size (diameter). In contrast, the copperhydroxide formed in solution by itself formed large particles andremained negatively charged.

After formation, the water was removed from the copper hydroxidemodified silica particle suspension under reduced pressure on a rotaryevaporator to leave a dry powder. This powder was washed with deionizedwater and filtered on a Buchner funnel three times before drying in aconvection oven at 100° C. The surface area of a sample of the powderwas determined by BET analysis (Micromeritics, Norcross, Ga.). Thecoating of copper hydroxide did not have an impact on the final surfacearea of the dried powder.

To determine the potential for urine odor reduction, 10 milligrams ofthe dried powder were placed in 12 Poise® pads (available fromKimberly-Clark) on the super absorbent/fluff pledget and then re-wrappedin the tissue wrap. The pads were then insulted with 60 milliliters ofpooled female urine and incubated for 24 hours in Mason jars (1 quart)with lids. 12 women panelists ranked the pads in order of most to leasturine odor intensity. Untreated Poise® and “Serenity Night & Day” pads(available from SCA Hygiene Products) were used as controls. The copperhydroxide modified silica nanoparticles powder (Snowtex-OXS-Cu(OH)₂) hadthe least urine odor of the samples. The good odor absorption of urineis believed to be due to the high surface of the nanoparticles combinedwith the effectiveness of copper in adsorbing amine and sulfurcompounds.

While the invention has been described in detail with respect to thespecific embodiments thereof, it will be appreciated that those skilledin the art, upon attaining an understanding of the foregoing, mayreadily conceive of alterations to, variations of, and equivalents tothese embodiments. Accordingly, the scope of the present inventionshould be assessed as that of the appended claims and any equivalentsthereto.

1. A substrate for reducing odor, said substrate containing silicaparticles bonded to a transition metal through a covalent or coordinatebond, wherein the mole ratio of the transition metal to the silicaparticles is at least about 10:1, said transition metal providing one ormore active sites for capturing an odorous compound; and wherein saidsilica particles have an average size of less than 100 nanometers.
 2. Asubstrate as defined in claim 1, wherein said transition metal isselected from the group consisting of scandium, titanium, vanadium,chromium, manganese, iron, cobalt, nickel, copper, zinc, silver, gold,and combinations thereof.
 3. A substrate as defined in claim 1, whereinan organofunctional silane bonds said transition metal to said silicaparticles.
 4. A substrate as defined in claim 3, wherein saidorganofunctional silane is covalently bonded to silanol groups presenton a surface of said silica particles.
 5. A substrate as defined inclaim 4, wherein said transition metal forms a coordinate bond with saidorganofunctional silane.
 6. A substrate as defined in claim 1, whereinsaid odorous compound is selected from the group consisting ofmercaptans, ammonia, amines, sulfides, ketones, carboxylic acids,aldehydes, terpenoids, hexanol, heptanal, pyridine, and combinationsthereof.
 7. A substrate as defined in claim 1, wherein the substratecomprises a nonwoven, woven, or paper web.
 8. A substrate as defined inclaim 1, wherein the solids add-on level of said modified silicaparticles is from about 0.001% to about 20%.
 9. An absorbent articlethat comprises the substrate of claim
 1. 10. An absorbent article asdefined in claim 9, further comprising at least one liquid-transmissivelayer and a liquid-absorbent core, wherein said substrate forms at leasta portion of said liquid-transmissive layer, said liquid-absorbent core,or combinations thereof.
 11. An absorbent article as defined in claim10, wherein the absorbent article includes a liquid-transmissive liner,a liquid-transmissive surge layer, a liquid-absorbent core, and avapor-permeable, liquid-impermeable outer cover, said substrate formingat least a portion of said liner, said surge layer, said absorbent core,said outer cover, or combinations thereof.
 12. A paper product thatcomprises the substrate of claim
 1. 13. A facemask that comprises thesubstrate of claim
 1. 14. A substrate as defined in claim 1, wherein thesilica particles have a surface area ranging from about 180 m²/g toabout 240 m²/g.
 15. A substrate for reducing odor, said substratecontaining silica particles bonded to at least one copper ion through acovalent or coordinate bond, wherein the mole ratio of copper ion to thesilica particles is at least about 10:1, said at least one copper ionproviding one or more active sites for capturing an odorous compound;and wherein the silica particles have a surface area ranging from about180 m²/g to about 240 m²/g.